Foil connector

ABSTRACT

An electrical connector for engagement preferably with relatively thin conductive material comprising, in one embodiment, a pair of generally planar interengaging members matingly arranged in spaced, opposing relationship. Each of preferably a plurality of preferably tapered piercing members selectively disposed adjacent a first surface of at least one of said members is arranged to penetrate through thin conductive material interposed between said members and extend into and be deformed about an associated selectively proportioned transverse aperture in the mating member as said members are compressively urged against the intervening conductive material, to establish a secure connection therebetween. Each of the members may be provided with one or more extending portions for coupling the connector to a further conductor or support member. Other embodiments include a multiple of spaced, interengaging members similarly comprising selectively disposed transverse apertures and mating piercing members.

United States Patent [191 Kuo [ 1 Aug. 14, 1973 FOIL CONNECTOR [75lnventor: Lai Che Kuo, Elizabeth, NJ.

[73 Assignee: Thomas & Betts Corporation,

Elizabeth, NJ.

[22] Filed: Aug. 23, 1971 [21] Appl. No.: 174,068

[52] US. Cl. 174/84 C, 339/95 R [51] Int. Cl H0lr 11/08 [58] Field ofSearch 339/95 R; 174/84 C,

174/94 R; 24/36, 265 A, 67, 153 HP Primary Examiner-Marvin A. ChampionAssistant Examiner--William F. Pate, Ill Attorney-David Teschner et a1.

[5 7] ABSTRACT An electrical connector for engagement preferably withrelatively thin conductive material comprising, in one embodiment, apair of generally planar interengaging members matingly arranged inspaced, opposing relationship. Each of preferably a plurality ofpreferably tapered piercing members selectively disposed adja cent afirst surface of at least one of said members is arranged to penetratethrough thin conductive material interposed between said members andextend into and be deformed about an associated selectively proportionedtransverse aperture in the mating member as said members arecompressively urged against the intervening conductive material, toestablish a secure connection therebetween. Each of the members may beprovided with one or more extending portions for coupling the connectorto a further conductor or support member. Other embodiments include amultiple of spaced, interengaging members similarly comprisingselectively disposed transverse apertures and mating piercing members.

4 Claims, 12 Drawing Figures Patented Aug. 14, 1973 3,752,901

2 Sheets-Sheet l INVENTOR.

L Al CHE KUO AGENT FOIL CONNECTOR BACKGROUND OF THE INVENTION l. Fieldof the Invention The invention is directed to the field of connectorsand principally to a connecting device for thin conductive material.

2. Description of the Prior Art Prior art connectors for electricalconductors or the like, generally comprised, in one form or another, agenerally deformable ferrule portion adopted to be mechanically crimpedabout the end of a conductor inserted therein. With the advent of thinconductive material commonly known as foil conductor, and the increasingemployment thereof in electrical wiring, a need for suitable means toeffect a secure mechanical and electrical connection to such materialwas recognized. Attempts to provide an adequate connection to thefoil-like material generally comprised joining by welding, brazing, orsoldering, which methods often proved to be expensive, time consuming,and inconvenient, requiring relatively specialized and cumbersomeequipment. Further, because of the fragile nature of the foil material,it was necessary to use extreme care in effecting the desired connectionby such means, to prevent damage thereto. The various embodiments oftoothed connectors developed for use with foil type material havegenerally been unsatisfactory because of the tendency of such connectorsto merely pierce and mechanically damage the material while failing toprovide adequate retention and protection adjacent the area ofconnection.

SUMMARY OF THE INVENTION The invention overcomes the problems andlimitations noted above with respect to such prior art connecting meansby providing a readily crimpable connector having interlocking piercingmembers and receiving apertures therefor suitably arranged to pierce andsecurely retain a portion of a foil material interposed between themembers thereof while affording an effective means for 'intercouplingsaid members. The connector may be formed as a single folded member, oras a series of interconnected spaced, generally planar members disposedin generally overlapping arrangement. Each of one or more foil-piercingmembers formed preferably as tapered protrusions extends outwardly froma surface of one member and is selectively proportioned for matingengagement with an associ ated transverse aperture in a mating member.Each member may be provided with a succession of altemating piercingmembers and apertures for engagement with a similar arrangement in themating member. Each of the tapered protrusions maybe appropriatelymodified to provide, for example, either a generally bifurcatedterminating end or a spear-like extension to enhance the desiredpenetration of the foil material and the subsequent deformation of thefree end of the piercing member adjacent its associated matingaperture.'The mating members maybe formed of any suitable materialadapted for use with conductive material, which may include copper,aluminum, brass or the appropriate alloys thereof, or a combination ofsuch materials.

In use, the mating members of the connector are disposed on either sideof a portion of the foil material to which such connector is to beattached, and compressed thereagainst by interposing the members betweenthe jaws of an appropriate tool. The free end of the piercing membersare thus caused to penetrate the foil and enter into and partiallyextend beyond an associated transverse aperture in the mating member,thus contacting an immediately adjacent portion of the compressing tooland deforming about the opening adjacent thereto. The resultantdeformation causes an expansion of said free end partially within thetransverse passage, and partially adjacent the opening formed by thecommunication of said passage with the surface of said member remotefrom the foil engaging surface, to lockingly engage the mating membersone to another while securely engaging the foil material therebetween.Upon the penetration of the piercing member therethrough, a portion ofthe foil material directly adjacent the piercing member is urged intothe respective transverse passage and effectively sandwiched between theadjacent passage wall and piercing member surface, thus affordingadditional engagement thereat. The portion of the foil materialextending beyond the transverse passage, after penetration, is caused toexpand outwardly beneath the deformed piercing member end toadditionally secure the foil material to the connector and improve theelectrical connection therebetween. Each transverse passage may besuitably recessed to permit the free end of the piercing member to be atleast partially deformed thereinto, thus providing a relatively smoothtransition between said endand the adjacent connector surface. Further,the area surrounding the opening formed by the communication of thetransverse passage with the foil engaging surface of the connector maybe appropriately raised to provide increased pressure thereat. It istherefore an object of this invention to provide an improved connector.

It is a further object of this invention to provide connecting means forrelatively thin material.

It is another object of this invention to provide an electricalconnector for foil conductors.

It is still another object of this invention to provide a mechanicallycrimpable connector having interengaging members.

It is still a further object of this invention to provide a multielementconnector for foil conductor material.

It is yet another object of this invention to provide a connector havingmeans arranged to pierce and securely retain foil conductor materialbetween the members thereof. I

It is still a further object of this invention to provide a connectorhaving disposed, on one member thereof, foil piercing means arranged topenetrate a foil conductor adjacent thereto and extend into and bedeformed about a receiving passage in a mating member to interengagablylock said members about the foil conductor.

Other objects and features will be pointed out in the followingdescription and claims and illustrated in the accompanying drawings,which disclose, by way of example, the principle of the invention andthe best mode contemplated for carrying it out.

BRIEF DESCRIPTION OF THE DRAWINGS In the Drawings FIG. I is aperspective view of a connector constructed in accordance with theconcepts of the invention.

FIG. 2 is a perspective view of another embodiment of a Connectorconstructed in accordance with the concepts of the invention.

FIG. 3 is a side elevational view of another embodiment of a connectorconstructed in accordance with the concepts of the invention. a

FIG. 4 is a perspective view, partly in section, of still anotherembodiment of a connector constructed in accordance with the concepts ofthe invention, as engaged about relatively thin material.

FIG. 5 is a fragmentary side elevational view, in section, of a piercingmember and associated aperture of a connector constructed in accordancewith the concepts of the invention, including a foil conductortherebetween.

FIG. 6 is a fragmentary side elevational view, in section, of theelements of FIG. 5 after assembly.

FIG. 7 is a fragmentary side elevational view, in section, of anotherembodiment of a piercing member and associated aperture of a connectorconstructed in accordance with the concepts of the invention, afterassembly to a foil material.

FIG. 8 is a fragmentary side elevational view, in section, of a furtherembodiment of a portion of a connector constructed in accordance withthe concepts of the invention.

FIG. 9 is a fragmentary side elevational view, in section, of theembodiment of FIG. 8 after assembly of the elements thereof to a foilmaterial.

FIG. 10 is a fragmentary side elevational view, in section, of stillanother embodiment of a portion of a connector constructed in accordancewith the concepts of the invention, as assembled to a foil material.

FIGS. 11 and 12 are fragmentary side elevational views, in section, ofstill further embodiments of piercing members of a connector constructedin accordance with the concepts of the invention.

Similar elements are given similar reference characters in each of therespective drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Turning now to FIG. 1, there isshown a connector constructed in accordance with the concepts of theinvention. Connector 20 comprises, essentially, coupled first and secondmembers 22 and 24, respectively, hingedly arranged in generallyoverlapping spaced relationship, substantially as shown. Piercingmembers 26 are disposed on a first surface 28 of member 22 and "extendupwardly therefrom generally normal to surface 28. Each piercing member26 is arranged for mating engagement with an associated aperture 30extending between the first and second surfaces 32 and 34, respectively,of second member 24, as said members 22 and 24 are compressively urgedtogether. Although shown as arranged in essentially alignedrelationship, piercing members 26 may be disposed in selectivelystaggered or scattered arrangement adjacent surface 28, as desired. Oneor more additional piercing members 36 similar to member 26, may beprovided adjacent the first surface 32 of member 24, each being arrangedfor engagement with an associated aperture 38 extending between thefirst and second surfaces, 28 and 39, respectively, of member 22.Piercing members 26 and 36 may be formed by lancing, as shown forexample in FIG. I, or by skiving orotherwise deforming the surface ofeither member 22 and 24, or, alternatively, by affixing said members tothe surface by welding, brazing, soldering, or other commonly employedmethods adaptable therefor. Each of the piercing members 26, 36 may beformed as a generally triangular element, substantially as shown in FIG.1, or may be suitably modified to provide a generally bifurcated memberas at 40 in FIG. 1 l, or a barbed-head configuration 42, as shown inFIG. 12, each being equally as effective for the use and purposes setforth herein. Each of the apertures 30 extending through connectormember 24 may be provided with a recessed portion 43 adjacently disposedthereabout, to receive the subsequently deformed free end of anassociated piercing member 26 in a manner more fully described below. Itwill be readily apparent that although apertures 30 are shown in FIG. 1as generally rectangular in shape, other alternative configurations suchas round or elliptical orifaces, for example, may be readily employedwhere convenient or desirable, without departing from the spirit of theinvention and within the concepts herein disclosed. An extending portionsuch as ferrule 44 may be affixed to or extend contiguously outwardlyfrom one or the other, or both, of connector members 22 and 24, althoughshown for convenience as extending from member22, whereit is desired toaffix connector 20 to a further article not readily engageable withinmembers 22 and 24. Where necessary or desirable, ferrule 44' may bereadily replaced by other suitable extensions appropriately adapted forinterengagement with,

for example, mating terminals, other connectors, or support members.

Referring now to FIGS. 2 and 3 there are shown further embodiments of aconnector 46, 48,- respectively, constructed in accordance with theconcepts of the invention. Connector 46 of FIG. 2 comprises threeselectively spaced generally overlapping members, 50, 52 and 54 eachjoined to an adjacent member preferably at one end to form a tailportion 56, which although not essential, may be apertured, as at 58, orotherwise configured, to provide a means for securing connector 46 to afurther connector or support member (not shown). Each of the members 50,52, 54 may be appropriately provided with piercing members such as 60and/or transverse apertures such as 62-in such combination andarrangement as to provide one or more sets of mating elements, each setcomprising a piercing member and a receiving aperture therefor. Eachpiercing member 60 is arranged for engagement with an associatedaperture 62 as members 50, 52 and 54 are urged together. It will bereadily apparent to those skilled in the art that members 50, 52 and 54may be conveniently co-joined in accordian-like fashion, where desired,the resulting structure being somewhat similar to that shown in FIG. 1,but differing, however, bythe addition of a further member coupled tomember 24 at the end thereof remote from the juncture between members 24and 22. Further, one or more pair of members similar to members 22 and24 of FIG. 1 may be co-joined thereto at the juncture of said members 22and 24, providing a plurality of independently crimpable connectorportions. Where necessary or desirable, at least one further member maybe added to the connector 46 of FIG. 2 to provide a connector such as48, as shown in FIG. 3, wherein the generally spaced overlapping members64, 66, 68 and 70 are essentially duplicative of members 50, 52 and 54of connector 46 and are similarly provided with mating piercing membersand apertures, as described above with respect to connectors and 46.

To more fully appreciate the concepts disclosed herein and at least onemanner of use of the device of the instant invention, reference is nowmade to FIGS. 4, 5 and 6 wherein, in FIG. 4, there is shown a connector72 interengagedly disposed about, and joining, the respective ends 74and 76 of a relatively thin material 78, 80 interposed within themembers 82, 84 of connector 72. To effect the connection shown, therespective ends 74 and 76 of the material to be joined are placedbetween connector members 82 and 84 in butting contacting arrangement,substantially as shown, or overlapped, if so desired. A compressiveforce is then applied to said members, by means of an appropriatelyformed tool (not shown) to cause each of the piercing members 86 topenetrate through the adjacent material 78, 80 and enter its respectiveaperture 88. The interrelationship between members 82 and 84, piercingmember 86 and its associated aperture 88, prior to penetration, is moreclearly shown in FIG. 5. As may be seen in more detail in FIG. 6, aportion of the material 78 generally overlying the piercing member 86prior to penetration is urged along with piercing member 86 intoaperture 88, and thereby locked within the gap therebetween, as shown at94 in FIG. 6. It should, of course, be readily apparent that thereference herein to material 78 applies equally as well to material 80.The end 96 of piercing member 86 extending beyond aperture 88 afterpenetration is caused to be enlargeably deformed in generallymushroom-like fashion upon its contact with the adjacent surface of thejaw of the compressive tool, or other similar device, (not shown)employed to close the connector members 82 and 84 upon the ends 74, 76respectively of material 78, 80. The deformation of the free end 96 ofpiercing member 86 about the opening of passage 88 adjacent theretofurther operates to intimately lock the connector members 82, 84together while securing the ends 74, 76 of material 78, 80,respectively, therebetween. It should be understood that where there aremore than two overlying, spaced connector members, as shown, forexample, in FIGS. 2 and 3, the free end of each of the piercing membersof one connector member may be suitably arranged to extend through itsmating aperture in the immediately adjacent connector member and impingeagainst the adjacent surface of the following connector member to effectthe deformation thereof similar to that shown in FIG. 6. As is furtherseen in FIG. 6, a portion 98 of the material 78 urged through aperture88 and extending therebeyond is caused to be foreibly displacedoutwardly against the immediately adjacent recessed portion 90 ofsurface 92 of member 84 as end 96 of piercing member 86 is deformedthereagainst, advantageously providing additional contact area betweenthe members 82 and 84 and the material 78 interposed therebetween. Wherenecessary or desirable, aperture 88 may be appropriately modified asshown, for example, in FIG. 10, wherein the aperture defining walls 100are selectively inclined to more closely match the generally taperedcontour of the mating piercing member 102, wherein, by the suitableproportioning of piercing member 102 and its mating aperture the portion104 of material 78 adjacent piercing member 102 is effectivelyintimately wedged within the gap between piercing member 102 and theaperture wall 100, and is additionally caused to undergo a less severebending than that resulting from the arrangement illustrated in FIGS. 5and 6. Consequently, any tendency for the material 78 to fracture ortear adjacent the area of angular deformation indicated as at 106 inFIG. 10 is thereby appreciably reduced, thus advantageously maintaininga continuous area of contact between said material and the surfaces ofthe connector immediately adjacent the zone of penetration. The wipingaction between the piercing member 102 and the adjacent surfaces 108 ofmaterial 78 upon penetration may be desirably increased by suitablyserrating, or otherwise providing discontinuities on the surface ofpiercing member 102. Where necessary or desirable, a recessed portionsuch as 90 (FIG. 5) may be provided adjacent aperture 88 to, forexample, accommodate the enlarged free end 96 of piercing member 86(FIGS. 5 and 6) after deformation, thus conveniently effecting arelatively smooth transition between the piercing member end 96 and thesurrounding connector surface. The recessed portion 90 may, of course,be eliminated, as shown, for example, in FIG. 7, the resultingconfiguration being useful in those applications where it may be desiredthat the resulting protrusion be disposed above the immediately adjacentconnector member surface. Where further engagement between the opposingconnector members 82, 84 and the material 78, 80 interposed therebetweenis desired, a raised portion 110 (FIGS. 8 and 9) generally surroundingthe piercing member receiving aperture 112 adjacent the opening thereofoverlying material 78, 80 may be provided. As shown in FIG. 9, upon theclosure of the opposing connector members 82, 84 about the material 78,the raised portion 110 is compressively urged against the immediatelyadjacent portion of material 78, thus providing additional engagementtherebetween. It should be readily apparent to those skilled in the artthat the various embodiments and arrangements described above andillustrated in FIGS. 5 through 12 may be readily employed in conjunctionwith any one of the connectors shown and described herein withoutdeparting from the spirit of the invention. It will be furtherappreciated that although the device of the instant invention will findsubstantial use as a connector for foil conductor material or the like,its use is not limited thereby, the device being equally as applicablefor use with either nonconductive or semiconductive materials where itis desired to effect merely a secure mechanical connector thereto.

The embodiments of the invention in which an exclusive property orprivelege is claimed are defined as follows:

I. A connection comprising: a connector having at least one first andsecond members, each having a first surface and a second surface, saidfirst surfaces being arranged in generally spaced, opposing relationshipto define an article receiving cavity therebetween; said second memberhaving at least one first transverse aperture therethrough, extendingbetween said first surface and said second surface thereof; a firstrecessed portion of substantially uniform depth completely surroundingsaid first transverse aperture adjacent the opening formed by thecommunication of said first transverse aperture and said second membersecond surface; a sheet of thin material situated between said first andsaid second members, and at least one first piercing means disposedadjacent said first member first surface and protruding outwardlytherefrom generally normal to the plane thereof, said first piercingmeans being dimensionally proportioned to fit closely within said firsttransverse aperture, the height of said first piercing means beinggreater than the thickness of said second member, said first piercingmeans terminating in a free end aligned with an associated firsttransverse aperture said first and second members being pressed togetherso that said first surfaces thereof are in intimate contact with saidsheet of thin material at least said free end of said first piercingmeans penetrating said sheet of thin material and expansively laterallydeformed within the area of said first recessed portion of saidassociated first transverse aperture to provide an enlarged head portionthereat seated in said first recessed portion and extending outwardlybeyond the area defined by the communication of said associated firsttransverse aperture and said second member second surface toindependently lock said first and said second members togetherintimately about said thin material.

2. A connection as defined in claim 1 wherein said first piercing meanscomprises a generally tapered member having its larger enddisposedadjacent said first member first surface.

3. A connection as defined in claim 1 further comprising a raisedshoulder portion surrounding said first transverse aperture adjacent theopening formed by the communication of said first transverse apertureand said second member first surface, said raised shoulder portioncommunicating generally with the base of an associated first piercingmeans upon the closure of said first and said second members, to furtherentrap a portion of such thin material therebetween.

4. A connection as defined in claim 1 further comprising an extendingportion coupled to at least one of said first and second members forcoupling said connector to a further article disposed adjacent theretov

1. A connection comprising: a connector having at least one first andsecond members, each having a first surface and a second surface, saidfirst surfaces being arranged in generally spaced, opposing relationshipto define an article receiving cavity therebetween; said second memberhaving at least one first transverse aperture therethrough, extendingbetween said first surface and said second surface thereof; a firstrecessed portion of substantially uniform depth completely surroundingsaid first transverse aperture adjacent the opening formed by thecommunication of said first transverse aperture and said second membersecond surface; a sheet of thin material situated between said first andsaid second members, and at least one first piercing means disposedadjacent said first member first surface and protruding outwardlytherefrom generally normal to the plane thereof, said first piercingmeans being dimensionally proportioned to fit closely within said firsttransverse aperture, the height of said first piercing means beinggreater than the thickness of said second member, said first piercingmeans terminating in a free end aligned with an associated firsttransverse aperture , said first and second members being pressedtogether so that said first surfaces thereof are in intimate contactwith said sheet of thin material at least said free end of said firstpiercing means penetrating said sheet of thin material and expansivelylaterally deformed within the area of said first recessed portion ofsaid associated first transverse aperture to provide an enlarged headportion thereat seated in said first recessed portion and extendingoutwardly beyond the area defined by the communication of saidassociated first transverse aperture and said second member secondsurface to independently lock said first and said second memberstogether intimately about said thin material.
 2. A connection as definedin claim 1 wherein said first piercing means comprises a generallytapered member having its larger end disposed adjacent said first memberfirst surface.
 3. A connection as defined in claim 1 further comprisinga raised shoulder portion surrounding said first transverse apertureadjacent the opening formed by the communication of said firsttransverse aperture and said second member first surface, said raisedshoulder portion communicating generally with the base of an associatedfirst piercing means upon the closure of said first and said secondmembers, to further entrap a portion of such thin material therebetween.4. A connection as defined in claim 1 further comprising an extendingportion coupled to at least one of said first and second members forcoupling said connector to a further article disposed adjacent thereto.